CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional Application No. 63/114,705, filed on November 17, 2020, the disclosure of which is hereby incorporated by reference herein in its entirety.

FIELD OF INVENTION

[0002] The present disclosure relates to an electrode in the form of a wire having integrated electrical contacts along a length that can be incorporated into a wearable device for medical applications or other applications, such as smart garments, in-ear devices, or external cardiac monitors.

BACKGROUND

[0003] Smart wearable devices are items of clothing or other items (e.g., earbuds, headsets, headgear, cardiac monitors, etc.) worn by a user which incorporate electrodes and any necessary wiring harness within the wearable item for continuous monitoring and/or treatment of a person while the item is worn. Electrodes that require adhesives are often impractical for use in wearable devices, and particularly for items that are worn for extended periods of time because conventional electrodes with adhesives can irritate the skin of a user and the adhesive can become less effective over time. In many wearable devices it is helpful if an electrode is relatively flexible to adhere to the contours of the body and allow for free movement. Convention wearable devices often have conductive traces formed of silver or other metal-based wires. Sometimes, traditional yarn coated with silver or other metals is used for the conductive traces.

[0004] Conventional electrode technology integrated with garments has fallen short for a number of reasons, including poor mechanical strength, low fatigue resistance, poor chemical stability, and poor washability. Moreover, conventional electrode components tend to be large and bulky with poor shielding. Accordingly, there is a need in the art for an electrode that is flexible, adherent, and that has good contact impedance for wearable devices, such as smart garments, which may have applications such as medical or monitoring devices.

SUMMARY [0005] One aspect of the present technology is a microcable comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum; and a layer of a conductive polymer surrounding the conductive core. [0006] Another aspect of the present technology is a wire electrode comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive layer through a via in the layer of electrically insulating polymer in at least one location along the wire. [0007] Another aspect of the present technology is a wearable garment comprising: a fabric configured to be worn by a user and at least one wire electrode integrated with the fabric. The wire electrode can comprise: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum; a dielectric layer of an electrically insulating polymer disposed around the conductive core, wherein the dielectric layer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the dielectric layer , wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive core through a via in the dielectric layer in at least one location along the wire. [0008] Another aspect of the present technology is a method of forming a wire electrode, comprising: (1) providing a wire comprising (a) a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum, and (b) a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; (2) ablating with a laser at least one via through the layer of an electrically insulating polymer to expose the at least one strand of a metal alloy comprising nickel, cobalt, chromium and molybdenum; and (3) depositing a layer of conductive polymer into the at least one via and onto the outer side of the layer of electrically insulating polymer such that the conductive polymer is in electrical communication with the conductive core through the via in the layer of electrically insulating polymer. [0009] Another aspect of the present technology is a conductive microcable comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel and chromium; and a layer of a conductive polymer surrounding the conductive core.

[0010] Another aspect of the present technology is a wire electrode comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel and chromium; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive later through a via in the layer of electrically insulating polymer in at least one location along the wire.

[0011] Another aspect of the present technology is a wearable garment comprising: a fabric configured to be worn by a user and at least one wire electrode integrated with the fabric. The wire electrode can comprise: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel and chromium; a dielectric layer of an electrically insulating polymer disposed around the conductive core, wherein the dielectric layer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the dielectric layer , wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive core through a via in the dielectric layer in at least one location along the wire.

[0012] Another aspect of the present technology is a method of forming a wire electrode, comprising: (1) providing a wire comprising (a) a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel and chromium, and (b) a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; (2) ablating with a laser at least one via thorough the layer of an electrically insulating polymer to expose the at least one strand of a metal alloy comprising nickel, cobalt, chromium and molybdenum; and (3) depositing a layer of conductive polymer into the at least one via and onto the outer side of the layer of electrically insulating polymer such that the conductive polymer is in electrical communication with the conductive core through the via in the layer of electrically insulating polymer. [0013] Another aspect of the present technology is a conductive microcable comprising: a conductive core comprising a strand comprising at least one wire comprising at least one conductive metal selected from the group consisting of platinum (Pt), gold (Au), silver (Ag), titanium (Ti), niobium (Nb), molybdenum (Mo), tungsten (W), rhenium (Re), copper (Cu), nickel (Ni), cobalt (Co), chromium (Cr), aluminum (Al), and alloys thereof; and a layer of a conductive polymer surrounding the conductive core.

[0014] Another aspect of the present technology is a wire electrode comprising: a conductive core comprising a strand comprising at least one wire comprising at least one conductive metal selected from the group consisting of platinum (Pt), gold (Au), silver (Ag), titanium (Ti), niobium (Nb), molybdenum (Mo), tungsten (W), rhenium (Re), copper (Cu), nickel (Ni), cobalt (Co), chromium (Cr), aluminum (Al), and alloys thereof; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive later through a via in the layer of electrically insulating polymer in at least one location along the wire.

[0015] Another aspect of the present technology is a wearable garment comprising: a fabric configured to be worn by a user and at least one wire electrode integrated with the fabric. The wire electrode can comprise: a conductive core comprising a strand comprising at least one wire comprising at least one conductive metal selected from the group consisting of platinum (Pt), gold (Au), silver (Ag), titanium (Ti), niobium (Nb), molybdenum (Mo), tungsten (W), rhenium (Re), copper (Cu), nickel (Ni), cobalt (Co), chromium (Cr), aluminum (Al), and alloys thereof; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive core through a via in the layer of electrically insulating polymer in at least one location along the wire.

[0016] The embodiments disclosed herein can be used alone or in combinations with each other.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS [0017] The following drawings are illustrative of embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments will hereinafter be described in conjunction with the appended drawings wherein like numerals/letters denote like elements.

[0018] FIG. 1 is an axial cross section view of one embodiment of a microcable as disclosed herein;

[0019] FIG. 2 is an axial cross section view of a second embodiment of a microcable as disclosed herein;

[0020] FIG. 3 is an axial cross section view of a third embodiment of a microcable as disclosed herein;

[0021] FIG. 4 is an axial cross section view of a fourth embodiment of a microcable as disclosed herein; and

[0022] FIG. 5 is a longitudinal cross section view of a wire electrode as disclosed herein.

DETAILED DESCRIPTION

[0023] The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides practical examples, and those skilled in the art will recognize that some of the examples may have suitable alternatives. Examples of construction methods, materials, dimensions and fabrication processes are provided for select elements, and other elements may employ materials known by those skilled in the art.

[0024] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

[0025] The use of the terms "a" and "an" and "the" and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any nonclaimed element as essential to the practice of the invention. The use of the term “comprising” in the specification and the claims includes the narrower language of “consisting essentially of” and “consisting of.”

[0026] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include any and all sub-ranges between and including the recited minimum value of 1 and the recited maximum value of 10, that is, all subranges beginning with a minimum value equal to or greater than 1 and ending with a maximum value equal to or less than 10, and all subranges in between, e.g., 1 to 6.3, or 5.5 to 10, or 2.7 to 6.1 .

[0027] Biomedical electrodes (referred to herein as simply “electrodes”) may be used for defibrillating, pacing, cardioversion, monitoring the activity of a subject's heart, and/or other neural sensing or neuromodulation applications (e.g., peripheral or spinal structures). Such applications can deliver therapy, such as TENS and tVNS, and/or sense neural activity. The electrodes disclosed herein are suitable for use on human subjects or patients, although use on non-human subjects is also contemplated. Examples of electrodes as disclosed herein can be coupled with power sources and control logic to deliver electrical energy to a subject, to determine the timing, levels, and history of applied energy, and to process monitored or detected data for analysis by, for example, a health care provider. Examples of electrodes as disclosed herein may be located proximate to the subject, for example, attached, connected, or coupled to the subject, at an anterior, posterior, lateral, or other location on the subject. For example, electrodes disclosed herein can be attached to the subject's chest, back, side, head (e.g., ear), abdomen, torso, thorax, or legs. In some embodiments, the electrodes disclosed are configured to be integrated into fabric to form a smart garment, i.e., a garment that monitors the wearer's physical condition or provides electrical stimulation if needed (e.g., defibrillation). For example, smart shirts and body suits can provide biometric data, such as pulse rate, temperature, muscle stretch, heart rhythm and physical movement, and the data are transmitted via Bluetooth to an app in real time. Examples of the wire electrodes disclosed herein may be compliant with the ANSI/AAMI DF80:2003 medical electrical equipment standard for the safety of cardiac defibrillators.

[0028] Hereinafter, preferred embodiments of the insulated wire of the present invention are described with reference to the drawings.

[0029] In one embodiment, a microcable comprises: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum; and a layer of a conductive polymer surrounding the conductive core.

[0030] Referring to FIG. 1 , a microcable 10 in accordance with an aspect of the present technology comprises a conductive core 2 comprising a strand comprising at least one wire 4 comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum. As used herein, the term “wire” is used interchangeably with the term “filament” and means a slender, string-like piece of relatively rigid or flexible metal, usually circular in cross section, that may be manufactured in a variety of diameters and metals depending on its application as disclose herein. As used herein, the term “strand” refers to an elongated or twisted and plaited body resembling a rope. A “strand” as used herein can include one wire or be formed by multiple wires twisted together.

[0031] In some embodiments shown in FIG. 1 , the conductive core 2 comprises one (i.e., a single) wire 4 comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum. In several applications, the metal alloy is a cobalt-based alloy with a high percentage of nickel, chromium, and molybdenum. One suitable alloy is commercially available under the trade name MP35N, which is an alloy comprising 35% Ni, 35% Co, 20% Cr, and 10% Mo. The MP35N alloy is characterized by an ultra-high tensile strength of up to 300 ksi (2070 mPa), and depending on the work-strengthening method used it exhibits good ductility, excellent toughness, and biocompatibility. This Ni/Co/Cr/Mo alloy can be used in the fully hardened condition at service temperatures up to 750 °F (400 °C). The MP35N alloy is generally easily bendable, formable, and pliable without breakage or fracturing. Due to the combination of cobalt, nickel, and molybdenum, the MP35N alloy has excellent stress corrosion cracking resistance, pitting corrosion resistance, grain boundary atack, and crevice corrosion resistance. The wire 4 comprises a metal alloy comprising nickel, cobalt, chromium and molybdenum functions to conduct an electric current from a control unit (not shown) to, for example, different sensors or electrodes via the conductive core 2. [0032] Due to the high strength of the MP35N alloy and its derivatives, the wire diameter can be largely decreased. Consequently, the stranded wire (for example in a 1x7 configuration) is likewise thin in diameter, offering small bending radii and good bendability while maintaining high mechanical robustness.

[0033] In some embodiments, the wire 4 comprises a metal alloy comprising nickel and chromium such as, for example, a stainless steel. In some embodiments, the wire 4 comprises at least one conductive metal selected from the group consisting of platinum (Pt), gold (Au), silver (Ag), titanium (Ti), niobium (Nb), molybdenum (Mo), tungsten (W), rhenium (Re), copper (Cu), nickel (Ni), cobalt (Co), chromium (Cr), aluminum (Al), and alloys thereof. For purposes of illustration, however, the following disclosure will focus on the metal alloy comprising nickel, cobalt, chromium and molybdenum, commercially known as MP35N.

[0034] FIG. 2 illustrates some embodiments of the microcable 10 in which the conductive core 2 comprises seven wires 4 comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum. This configuration is referred to as a 1x7 configuration. FIG. 3 illustrates some embodiments of the microcable 10 wherein the conductive core 2 comprises six wires 4 comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum and one center wire that is a silver filament 12. Although the silver filament 12 is shown in the center, it could be at any location in the conductive core 2. The silver 12 filament functions to increase the overall conductivity of the microcable 10.

[0035] In some embodiments, such as any of the foregoing embodiments as an example, the MP35N alloy is clad with Ag and Pt (not shown) to form MP35N/Ag and MP35N/Pt. The cladding material is expected to lower resistivity and X-ray opacity to increase the efficacy and detection of the microcables in images.

[0036] Referring to FIGS. 1 to 3, the microcable 10 can further include a layer of a conductive polymer 6 surrounding at least a portion of the conductive core. The conductive polymer layer 6 functions, at least in part, to provide an EMI shielding around the microcable. As such, the conductive polymer layer 6 is often the outer most layer of the microcable 10. The conductive polymer used for conductive polymer layer 6 is preferably a biocompatible conductive polymer that is electrically conductive once a current is applied and that is mechanically stable over one or more periods of wear. Examples of materials used for conductive polymers include polynaphthalene, polythiophene, Nation, polyethylene oxide, and polyethyldioxythiophene (PEDOT). Other classes of conductive polymers include polyacetylenes, conductive polypyrrole polystyrene sulfonate, polythiophenes (PT), and polyanilines. Conductive polymers may also include EHPT (poly(3-(2-ethylhexyl)thiophene), ionomers (e.g., NAFION®), poly(3,4 ethylene dioxythiophene) (PEDOT) and PEDOT polystyrene sulfonate (PSS/PEDOT), polyacrylamide, and polyvinylpyrrolidone, and mixtures thereof. The conductive polymers are biocompatible (e.g., the polymers are not toxic or injurious to living tissue). In some embodiments, PEDOT/PSS is the preferred conductive polymer.

[0037] The conductive polymer layer 6 for purposes of the present technology can also comprise a non-conductive polymer doped with an electrically conductive filler. The electrically conductive fillers can be, for example and without limitation, carbon black and other known carbons, gold, silver, aluminum, copper, chromium, nickel, platinum, tungsten, titanium, iron, zinc, lead, molybdenum, selenium, indium, bismuth, tin, magnesium, manganese, cobalt, titanium germanium, and the like.

[0038] In some embodiments, dopants may be added to the conductive polymer layer 6 to enhance the conductivity of the polymer and provide a lower energy threshold for conductivity. Dopants may also help to specifically control the conductivity characteristics. There are many methods and materials useful in doping that may be known to those skilled in the art. Doping materials can include, but are not limited to chloride, polystyrene sulfonate (PSS), dodecylbenzenesulfonate, polystyrenesulfonate, naphthalene sulfonate, and lithium perchlorate.

[0039] A conductive polymer composition comprising PEDOT, for example, is known to be biocompatible, skin-friendly, washable and wear-resistant. Due to its inherent conductivity, it is effective as an EMI shield and due to its durability and biocompatibility, no additional polymer cover is required. Therefore, the overall diameter and thus bendability can be further miniaturized when compared to conventional cables. For example, in some embodiments, the overall diameter of the microcable 10 will be from about 60 pm to about 600 pm, or from about 100 pm to about 200 pm. Of this overall diameter, the thickness of conductive polymer layer can be from about 0.3 pm to about 50 pm, or from about 1 .0 pm to about 25 pm.

[0040] FIG. 4 shows another embodiment of the microcable 10 similar to the embodiment shown in FIG. 1 , however the microcable 10 shown in FIG. 4 includes a dielectric layer 8 of an electrically insulating polymer (also referred to herein as a dielectric insulator) between the conductive core 2 and the conductive polymer layer 6. The dielectric layer 8 can include dielectric polymers suitable for use as dielectric insulators, such as silicone rubber, polyurethane, polyester resin, polyimide, artificial rubber, epoxy resin, polydimethylsiloxane, polyurethane and ethylene glycol terephthalate or polymethyl methacrylate or any of their combinations. Polymers that are elastomers may be particularly well suited for the dielectric layer 8. The term “elastomer” in the descriptions herein, refers to a material that changes properties in response to an applied force. Elastomers, in various formulations, respond to normal forces, compression, torque, or sheer stresses or forces. Some elastomers are also referred to as “rubber,” “polymer,” or “silicone.” Typically, but not always, an elastomer responds to an applied force with a physical deformation. Elastomers can be configured to change properties when stressed in one dimension, or in multiple dimensions.

[0041] Other synthetic polymers for the dielectric layer 8 include polymers made from, or comprising, for example: ETFE (a coating made from a copolymer of Ethylene and TetraFluoroEthylene better known as Tefzel®), poly(ethylene) oxide, polyethylene glycol, polyvinyl pyrrolidinone, polyacrylate, polymethylacrylate, polyalkylene oxide, methacrylic acid or other vinylic monomers, an acyl chloride, for example methacryloyl chloride, an isocyanate, or 2- isocyanatoethyl methacrylate an electrophilic poly(ethylene glycol) methacrylate (PEGMA). Free radical polymerization is, in general, accomplished with a vinylic or allylic group, including acrylates and methacrylates. A monomer may be polymerized by itself or with co-monomers that also undergo free radical polymerization. Examples of co-monomers include one or more of: acrylates, methacrylates, 2-hydroxyethyl methacrylate, hydroxypropyl methacrylate, n-butyl methacrylate, tert-butyl methacrylate, n-hexyl methacrylate, 2-methoxyethyl methacrylate, poly(hexanide) methacrylate, poly(hexanide) polyethylene oxide methacrylate, or alkyl derivatized poly(hexanide) methacrylate, heparin derivatized polyethylene oxide macromer, vinyl sulfonic acid monomer, monomers comprising poly(ethylene glycol), N-vinyl pyrrolidone monomers, 4- benzoylphenyl methacrylate allyl methyl carbonate, allyl alcohol, allyl isocyanate, methacryloyloxyethyl phosphorylcholine, glycerol monomethacrylate, and polymers containing phosphate and amine moieties. Various polymers include, for instance: hydrophilic polymers, hydrophobic polymers, polyalkylene oxides, polyethylene oxide, polyethers, and polyvinylpyrrolidone.

[0042] In embodiments where the dielectric layer 8 of the electrically insulating polymer is present, the layer may have a thickness of, for example, from about 10 pm to about 100 pm, and preferably from about 20 pm to about 50 pm. The dielectric layer 8 can have a thickness such that the overall diameter of the microcable 10 should still be from about 60 pm to about 600 pm, or from about 100 pm to about 200 pm. The embodiments of the microcable 10 shown in FIGS. 2 and 3 with conductive core 2 having multiple wires 4 can also include the dielectric layer 8 between the conductive core 2 and the conductive polymer layer 6. [0043] The above-disclosed microcables 10 can be woven into nets similar to Pt catalyst nets, to be incorporated into smart garments as electrodes that can measure, for example, ECG, EEG, or EMG signals. In other embodiments, the microcables 10 can be singles cables or multiple parallel cables. [0044] The present technology also includes wire electrodes comprising a conductive core, a dielectric layer around the conductive core, and a conductive polymer material on at least a portion of the dielectric layer. The conductive core can comprise a strand having at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum, The dielectric layer can comprise an electrically insulating polymer with an inner side facing the conductive core, an outer side, and a via extending from the outer side to the inner side. The conductive polymer material can be disposed on the outer side of the dielectric layer such that at least a portion of the conductive polymer material is in the via such that the conductive polymer material is in electrical communication with the conductive core along at least one location of the wire. [0045] FIG.5 and FIG.6 illustrate an embodiment of a wire electrode 20 in accordance with the present technology. In this embodiment, the microcable is used as the sensing electrode itself without the need to attach an additional separate electrode. The wire electrode 20 can comprise a conductive core 2 comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum. As described above, the metal alloy can be a cobalt-based alloy with a high percentage of nickel, chromium, and molybdenum, commercially available under the trade name MP35N, which comprises 35% Ni, 35% Co, 20% Cr, and 10% Mo. The MP35N alloy is characterized by an ultra-high tensile strength of up to 300 ksi (2070 mPa), depending on the work-strengthening method used, good ductility, excellent toughness, and biocompatibility. This alloy can be used in the fully hardened condition at service temperatures up to 750 °F (400 °C). The MP35N alloy is generally easily bendable, formable, and pliable without breakage or fracturing. In combination with cobalt and nickel, the MP35N alloy shows excellent stress corrosion cracking resistance, pitting corrosion resistance, grain boundary attack, and crevice corrosion resistance. The one or more wires comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum functions to conduct an electric current from a control unit (not shown) to, for example, different sensors or electrodes via the conductive core 2. In some embodiments, the molybdenum (e.g., the MP35N alloy) is clad with Ag and Pt (not shown) to form MP35N/Ag and MP35N/Pt clad material which will give other advantages such as lower resistivity and X-ray opacity. [0046] As is shown in FIG. 2, the conductive core 2 shown in the embodiment of FIG. 6 may comprise multiple wires 4, such as seven wires, comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum. This configuration is referred to as a 1x7 configuration. In an alternative embodiment to that of FIG. 6, the conductive core 2 may comprises six wires 4 comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum and one center wire that is a silver filament (not shown) as was described above with reference to FIG. 3.

[0047] Referring to FIG. 5, the wire electrode 20 can comprise the dielectric layer 8 of an electrically insulating polymer. The dielectric layer 8 can include any of the above-mentioned dielectric polymers or another electrically insulating polymer not listed above. The dielectric layer 8 electrically insulates the core 2 and can include a via or pathway in which an electrode can be formed from a conductive polymer as will be explained in greater detail below.

[0048] An example of a 1x7 MP35N/Ag 28% ETFE coated cable’s dimensional, mechanical and physical properties are listed in the following tables. The cable is typically supplied on DIN125 spools.

[0049] To form the wire electrode of FIG. 5, a via 22 or pathway is created through the dielectric layer 8 to the conductive core 2. As with the embodiments described above, the dielectric layer 8 can include an electrically insulating polymer (e.g., ETFE) and the conductive core 2 can comprises a strand having at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum. The via 22 defines an opening through which the metal alloy of the conductive core 2 is exposed. Due to the size of the wire, the via 22 can be created by laser ablation using, for example, a UV nano laser. For example, the Nanio 355-3-V available from Innolas Photonics can be used to laser ablate the via 22. Such a UV nano laser has a wavelength of 355 nm and a peak power of about 3 Watts. The via 22 may be in one discrete local on the wire that does not extend around the full circumference of the conductive core 2 or it may be formed as a channel that extends around the diameter (i.e. , full circumference) of the conductive core 2. Moreover, more than one via 22 can be ablated to expose selective and distinct regions along the conductive core 2, or in the case where the conductive core 2 has multiple wires 4 more than one via 22 can be formed such that one or more vias 22 exposed individual wires 4.

[0050] Still referring to FIG. 5, the via 22 is filled with a conductive polymer to form an individual electrode contact 24. The conductive polymer layer 6 functions, at least in part, to be in electrical communication with the conductive core 2 to conduct an electric current from and/or to a person in contact with the wire electrode contact 24. The conductive polymer used to create the electrode contact 24 is preferably a biocompatible conductive polymer that is electrically conductive once a current is applied and that is mechanically stable over a period or multiple periods of wear. Examples of conductive polymers that can be used for the electrode contact 24 include polynaphthalene, polythiophene, Nation, polyethylene oxide, and polyethyldioxythiophene (PEDOT). Other classes of conductive polymers include polyacetylenes, conductive polypyrrole polystyrene sulfonate, polythiophenes (PT), and polyanilines. Conductive polymers may also include EHPT (poly(3-(2-ethylhexyl)thiophene), ionomers (e.g., NAFION®), poly(3,4 ethylene dioxythiophene) (PEDOT) and PEDOT polystyrene sulfonate (PSS/PEDOT), polyacrylamide, and polyvinylpyrrolidone, and mixtures thereof. The conductive polymers are biocompatible (e.g., the polymers are not toxic or injurious to living tissue). In some embodiments, PEDOT/PSS is the preferred conductive polymer.

[0051] In some embodiments, dopants may be added to the conductive polymer for the electrode contact 24 to enhance the conductivity of the polymer and provide a lower energy threshold for conductivity. Dopants may also help to specifically control the conductivity characteristics. There are many methods and materials useful in doping that may be known to those skilled in the art. Doping materials can include, but are not limited to chloride, polystyrene sulfonate (PSS), dodecylbenzenesulfonate, polystyrenesulfonate, naphthalene sulfonate, and lithium perchlorate.

[0052] The conductive polymer for the electrode contact 24 is preferably deposited into via 22 by an electrodeposition process (also referred to herein as “electropolymerization”) as is known to those skilled in the art. As used herein “electrodeposition” is the deposition of a material that occurs upon the application of an electrical potential between two conductive materials (or electrodes) within a liquid medium containing charged species. In various embodiments, materials are electrodeposited at the anode (i.e., the electrode where monomer oxidation takes place). A typical apparatus for carrying out electrodeposition includes the following: an anode, a cathode and, frequently, a reference electrode, each separated by an electrolyte (e.g., an ion containing solution), as well as a potentiostat which monitors/sets the voltages/currents at the various electrodes. Electrodeposition can be carried out under a variety of electrochemical conditions including the following, among others: (a) constant current, (b) constant voltage, (c) current scan/sweep, e.g., via a single or multiple scans/sweeps, (d) voltage scan/sweep, e.g., via a single or multiple scans/sweeps, (e) current square waves or other current pulse wave forms, (f) voltage square waves or other voltage pulse wave forms, and (g) a combination of different current and voltage parameters.

[0053] The conductive core 2 is in electrical connection with a terminal (not shown) via a conducting element (not shown) such as, for example, a wire, which electrically connects the electrode to a current delivery device (not shown). The current delivery device may contain electronics to sense various electrical signals of a particular body part such as, for example, the heart or the brain, and also to produce current pulses for delivery to a body part such as, for example, the heart or brain via the connecting element. The current delivery device may contain electronics to sense various electrical signals from a particular body part or tissue such as the heart or the brain and to also produce current pulses for delivery to a body part or tissue as desired. The current delivery device, for example, can have a housing configured to be attached to an ear of a human and position one or more electrode contacts in the ear canal.

[0054] A method of forming a wire electrode can comprise providing a wire having a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum. The method can further include disposing a dielectric layer comprising an electrically insulating polymer around the conductive core such that the dielectric layer has an inner side facing the conductive core and an outer side. The method can continue by ablating with a laser at least one via thorough the dielectric layer to expose the at least one strand of a metal alloy comprising nickel, cobalt, chromium and molybdenum. The method also includes depositing a conductive polymer material into the at least one via and onto the outer side of the dielectric layer such that the conductive polymer material is in electrical communication with the conductive core through the via in the dielectric layer.

[0055] Electrodes in accordance with the present disclosure may include additional features that are not illustrated, for example, adhesive layers bonding the various components of the electrode together, labeling, a mechanism for holding the electrical conductor in place and in electrical contact with the conductive element, and/or packaging. Components of electrodes in accordance with examples of the present disclosure may be formed from materials having certain desirable properties. Further, electrodes in accordance with the present disclosure may communicate wirelessly with circuitry.

[0056] The electrodes disclosed herein may also be incorporated into a wearable device, such as a smart garment, earpiece, headset, etc., which may serve as a medical device (e.g., a monitoring and/or stimulation device) or other types of devices. As an example, a smart garment incorporating the electrodes disclosed herein may be used for measuring ECG, EEG, or EMG signals in a patient. Accordingly, the present disclosure includes the disclosure of a wearable device comprising: a fabric configured to be worn by a person and at least one wire electrode integrated with the fabric. The wire electrode can comprise a conductive core, a dielectric layer disposed around the core, and a conductive polymer material in and/or on at least a portion of the dielectric layer. The conductive core can comprise a strand having at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum. The dielectric layer can comprise an electrically insulating polymer having an inner side facing the conductive core, an outer side and a via from the outer side to the inner side. The conductive polymer material can be disposed in the via of the dielectric layer such that the conductive polymer material is in electrical communication with the conductive core through the via in the dielectric layer.

[0057] Examples of wearable devices that could be “smart garments” according to the present technology include a shirt, a vest, a belt, a strap, a hat, pants, shorts, a skirt, a backpack, an undergarment, and any other suitable form of garment. Each of these exemplary garments is comprised of a fabric configured to conform to the specific body part or region. The fabric could be, for example, cotton, wool, polyester, any type of denim, flannel, nylon, and mixtures thereof.

[0058] A wearable device, such as a smart garment, including the microcables and/or the wire electrodes disclosed herein can be made by integrating either the microcable or the wire electrode disclosed herein with the particular fabric used for the garment such that the electrodes are located such that they will be in contact with the skin of the wearer. Examples of wearable garments include those found in U.S. Patent No. 9,545,514, the disclosure of which is incorporated herein by reference.

EXAMPLES

[0059] Example 1 : Preparation of a Wire Electrode [0060] First, a molybdenum wire, such as a wire made from the MP35N alloy, is drawn in multiple steps down to 25.4 pm diameter and seven filaments are subsequently stranded into one 1x7 conductive core. The wire is then coated with a dielectric material forming a dielectric layer.

[0061] Second, the dielectric material can be polyurethane the outer diameter of the dielectric material is 127 pm.

[0062] Third, one or more areas of the dielectric material are selectively ablated to form one or more vias using a UV nano laser Innolas Photonics Nanio 355-3-V with a wavelength of 355 nm and a peak power of 3W in cooperation with a Raylase 2-axis scanning unit Superscan IV. Using a repetition frequency of 40 kHz and a scan speed of 400 mm/s, a rectangular area of 40x40 pm ² is scanned in 6 passes, thus, access through the vias is created to the conductive core of the wire.

[0063] Fourth, the remaining portions of the dielectrid material are masked with adhesive foil prior to coating to protect those areas that are not supposed to be coated.

[0064] Then, fifth, the surface areas that are intended to be coated are activated to allow for a proper wetting. Depending on the substrate material, the procedure may vary, comprising both chemical and physical means to activate the substrate. For the former, a chemical treatment with H2O2 is an option while physical treatments may encompass low pressure oxygen plasma exposure or UV treatment, for example, for 2 min with a 172 nm radiation.

[0065] Sixth, the previously masked and properly primed surface is coated with Tecticoat™ conductive polymer using a spraycoating gun “Krautzberger Handspritzapparat Mignon 4S” with 1.5 bar pressure, 9cm working distance, 10 sec spraying time, and one full rotation of the wire. The respective liquid film will have a thickness on the order of 20 pm to 30 pm.

[0066] Seventh, the parts are dried for 10 min at 100 °C in a box oven so that the volatile solvents are evaporated, and the film is cured to form a solidified layer of about 0.3 pm to 1 .0 pm thickness. The fifth to seventh steps are repeated to account for any inhomogeneity in coating thickness that may be caused, for example, by the orientation of the wire during drying.

[0067] The masking tape is then removed and the electrode may be packed for storage.

[0068] In the foregoing detailed description, the invention has been described with reference to specific embodiments. However, it will be appreciated that various modifications and changes can be made without departing from the scope of the invention as set forth in the appended claims. CLAUSES

[0069] The present technology is illustrated, for example, according to various aspects described below. Various examples of aspects of the present technology are described as numbered clauses (1 , 2, 3, etc.) for convenience. These are provided as examples and do not limit the present technology. It is noted that any of the dependent clauses may be combined in any combination, and placed into a respective independent clause. The other clauses can be presented in a similar manner. A conductive microcable comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum; and a layer of a conductive polymer surrounding the conductive core. The conductive microcable of clause 1 further comprising a layer of an electrically insulating polymer disposed between the conductive core and the layer of conductive polymer. The conductive microcable of any of clauses 1-2 wherein the conductive polymer comprises poly(3,4-ethylenedioxythiophene) (PEDOT). The conductive microcable of clause 3 wherein the conductive polymer further comprises PSS. The conductive microcable of clause 2 wherein the layer of electrically insulating polymer comprises an elastomer. The conductive microcable of any of clauses 1-5 wherein the strand comprises from one to seven wires of the metal alloy comprising nickel, cobalt, chromium and molybdenum. The conductive microcable of any of clauses 2-6 wherein the layer of electrically insulating polymer comprises at least one polymer selected from the group consisting of polyurethanes (PU), polyester (PET), polyamide (PA), polycarbonates (PC), polyimides, fluorinated polymers, polyether-ether-ketone (PEEK), poly-p-xylylene (parylene), polymethyl methacrylate (PMMA), PTFE (polytetrafluoroethylene), FEP (perfluorinated propylene), PFA (perfluoroalkoxy copolymer resin), THV (tetrafluoroethylene, hexafluoropropylene, vinylidene fluoride), PVDF (polyvinylidene fluoride vinylidene), EFEP (ethylene propylene fluorinated ethylene) and ETFE (ethylene tetrafluoroethylene). The conductive microcable of any of clauses 1-7 wherein the strand comprises seven wires wherein at least one wire comprises silver and the remaining wires comprise the metal alloy comprising nickel, cobalt, chromium and molybdenum. The conductive microcable of any of clauses 1-8 wherein the at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum is a MP35N wire. The conductive microcable of any of clauses 1-9 wherein the microcable has a diameter of from 60 pm to 600 pm. The conductive microcable of clause 10 wherein the microcable has a diameter of from 100 pm to 200 pm. The conductive microcable of clause 11 wherein the layer of conductive polymer has a thickness of from 0.3 pm to 50 pm. A wire electrode comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive later through a via in the layer of electrically insulating polymer in at least one location along the wire. The wire electrode of clause 13 wherein the at least a partial layer of conductive polymer extends around the circumference of the wire at the at least one location along the wire. The wire electrode of any of clauses 13-14 further comprising a layer of an electrically insulating polymer disposed between the conductive core and the layer of conductive polymer. The wire electrode of any of clauses 13-15 wherein the conductive polymer comprises poly(3,4- ethylenedioxythiophene) (PEDOT). The wire electrode of clause 16 wherein the conductive polymer further comprises PSS. The wire electrode of any of clauses 15-17 wherein the layer of electrically insulating polymer comprises an elastomer. The wire electrode of any of clauses 13-18 wherein the strand comprises from one to seven wires of the metal alloy comprising nickel, cobalt, chromium and molybdenum. The wire electrode of any of clauses 15-19 wherein the layer of electrically insulating polymer comprises at least one polymer selected from the group consisting of polyurethanes (Pll), polyester (PET), polyamide (PA), polycarbonates (PC), polyimides, fluorinated polymers, polyether-ether-ketone (PEEK), poly-p-xylylene (parylene), polymethyl methacrylate (PMMA), PTFE (polytetrafluoroethylene), FEP (perfluorinated propylene), PFA (perfluoroalkoxy copolymer resin), THV (tetrafluoroethylene, hexafluoropropylene, vinylidene fluoride), PVDF (polyvinylidene fluoride vinylidene), EFEP (ethylene propylene fluorinated ethylene) and ETFE (ethylene tetrafluoroethylene). The wire electrode of any of clauses 13-20 wherein the strand comprises seven wires wherein at least one wire comprises silver and the remaining wires comprise the metal alloy comprising nickel, cobalt, chromium and molybdenum. The wire electrode of any of clauses 13-21 wherein the at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum is a MP35N wire. The wire electrode of any of clauses 13-22 wherein the microcable has a diameter of from 60 pm to 600 pm. The wire electrode of clause 23 wherein the microcable has a diameter of from 100 μm to 200 pm. The wire electrode of clause 24 wherein the layer of conductive polymer has a thickness of from 0.3 pm to 50 pm. A wearable garment comprising: fabric; at least one wire electrode integrated with the fabric, the wire electrode comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive core through a via in the layer of electrically insulating polymer in at least one location along the wire. The wearable garment of clause 26 wherein the at least a partial layer of conductive polymer extends around the circumference of the wire at the at least one location along the wire. The wearable garment of any of clauses 26-27 wherein the conductive polymer comprises poly(3,4-ethylenedioxythiophene) (PEDOT). The wearable garment of clause 28 wherein the conductive polymer further comprises PSS. The wearable garment of any of clauses 26-29 wherein the layer of electrically insulating polymer comprises an elastomer. The wearable garment of any of clauses 26-30 wherein the strand comprises from one to seven wires of the metal alloy comprising nickel, cobalt, chromium and molybdenum. The wearable garment of any of clauses 26-31 wherein the layer of electrically insulating polymer comprises at least one polymer selected from the group consisting of polyurethanes (Pll), polyester (PET), polyamide (PA), polycarbonates (PC), polyimides, fluorinated polymers, polyether-ether-ketone (PEEK), poly-p-xylylene (parylene), polymethyl methacrylate (PMMA), PTFE (polytetrafluoroethylene), FEP (perfluorinated propylene), PFA (perfluoroalkoxy copolymer resin), THV (tetrafluoroethylene, hexafluoropropylene, vinylidene fluoride), PVDF (polyvinylidene fluoride vinylidene), EFEP (ethylene propylene fluorinated ethylene) and ETFE (ethylene tetrafluoroethylene). The wearable garment of any of clauses 26-32 wherein the strand comprises seven wires wherein at least one wire comprises silver and the remaining wires comprise the metal alloy comprising nickel, cobalt, chromium and molybdenum. The wearable garment of any of clauses 26-33 wherein the at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum is a MP35N wire. The wearable garment of any of clauses 26-34 wherein the microcable has a diameter of from 60 pm to 600 pm. The wearable garment of clause 35 wherein the microcable has a diameter of from 100 pm to 200 pm. The wearable garment of clause 36 wherein the layer of conductive polymer has a thickness of from 0.3 pm to 50 pm. A method of forming a wire electrode, the method comprising the steps of: providing a wire comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum; and a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; ablating with a laser at least one via thorough the layer of an electrically insulating polymer to expose the at least one strand of a metal alloy comprising nickel, cobalt, chromium and molybdenum; depositing a layer of conductive polymer into the at least one via and onto the outer side of the layer of electrically insulating polymer such that the conductive polymer is in electrical communication with the conductive core through the via in the layer of electrically insulating polymer. The method of clause 38 wherein the depositing step comprises an electrochemical deposition in an area provided by a mask. The method of any of clauses 38-39 wherein the conductive polymer comprises poly(3,4- ethylenedioxythiophene) (PEDOT). The method of clause 40 wherein the conductive polymer further comprises PSS. The method of any of clauses 38-41 wherein the layer of electrically insulating polymer comprises an elastomer. The method of any of clauses 38-42 wherein the strand comprises from one to seven wires of the metal alloy comprising nickel, cobalt, chromium and molybdenum. The method of any of clauses 38-43 wherein the layer of electrically insulating polymer comprises at least one polymer selected from the group consisting of polyurethanes (Pll), polyester (PET), polyamide (PA), polycarbonates (PC), polyimides, fluorinated polymers, polyether-ether-ketone (PEEK), poly-p-xylylene (parylene), polymethyl methacrylate (PMMA), PTFE (polytetrafluoroethylene), FEP (perfluorinated propylene), PFA (perfluoroalkoxy copolymer resin), THV (tetrafluoroethylene, hexafluoropropylene, vinylidene fluoride), PVDF (polyvinylidene fluoride vinylidene), EFEP (ethylene propylene fluorinated ethylene) and ETFE (ethylene tetrafluoroethylene). The method of any of clauses 38-44 wherein the strand comprises seven wires wherein at least one wire comprises silver and the remaining wires comprise the metal alloy comprising nickel, cobalt, chromium and molybdenum. The method of any of clauses 38-45 wherein the at least one wire comprising a metal alloy comprising nickel, cobalt, chromium and molybdenum is a MP35N wire. The method of any of clauses 38-46 wherein the microcable has a diameter of from 60 pm to 600 pm. The method of clause 47 wherein the microcable has a diameter of from 100 pm to 200 pm. The method of clause 48 wherein the layer of conductive polymer has a thickness of from 0.3 pm to 50 pm. A conductive microcable comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel and chromium; and a layer of a conductive polymer surrounding the conductive core. A wire electrode comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel and chromium; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive later through a via in the layer of electrically insulating polymer in at least one location along the wire. A wearable garment comprising: fabric; at least one wire electrode integrated with the fabric, the wire electrode comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel and chromium; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive core through a via in the layer of electrically insulating polymer in at least one location along the wire. A method of forming a wire electrode, the method comprising the steps of: providing a wire comprising: a conductive core comprising a strand comprising at least one wire comprising a metal alloy comprising nickel and chromium; and a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; ablating with a laser at least one via thorough the layer of an electrically insulating polymer to expose the at least one strand of a metal alloy comprising nickel, cobalt, chromium and molybdenum; depositing a layer of conductive polymer into the at least one via and onto the outer side of the layer of electrically insulating polymer such that the conductive polymer is in electrical communication with the conductive core through the via in the layer of electrically insulating polymer. A conductive microcable comprising: a conductive core comprising a strand comprising at least one wire comprising at least one conductive metal selected from the group consisting of platinum (Pt), gold (Au), silver (Ag), titanium (Ti), niobium (Nb), molybdenum (Mo), tungsten (W), rhenium (Re), copper (Cu), nickel (Ni), cobalt (Co), chromium (Cr), aluminum (Al), and alloys thereof; and a layer of a conductive polymer surrounding the conductive core. A wire electrode comprising: a conductive core comprising a strand comprising at least one wire comprising at least one conductive metal selected from the group consisting of platinum (Pt), gold (Au), silver (Ag), titanium (Ti), niobium (Nb), molybdenum (Mo), tungsten (W), rhenium (Re), copper (Cu), nickel (Ni), cobalt (Co), chromium (Cr), aluminum (Al), and alloys thereof; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive later through a via in the layer of electrically insulating polymer in at least one location along the wire. A wearable garment comprising: fabric; at least one wire electrode integrated with the fabric, the wire electrode comprising: a conductive core comprising a strand comprising at least one wire comprising at least one conductive metal selected from the group consisting of platinum (Pt), gold (Au), silver (Ag), titanium (Ti), niobium (Nb), molybdenum (Mo), tungsten (W), rhenium (Re), copper (Cu), nickel (Ni), cobalt (Co), chromium (Cr), aluminum (Al), and alloys thereof; a layer of an electrically insulating polymer disposed around the conductive core, wherein the layer of electrically insulating polymer has an inner side and an outer side, wherein the inner side faces the conductive core; and at least a partial layer of conductive polymer disposed on the outer side of the layer of electrically insulating polymer, wherein the at least a partial layer of conductive polymer is in electrical communication with the conductive core through a via in the layer of electrically insulating polymer in at least one location along the wire.